Composite bodywork developed from vehicle packaging and surface CAD through CNC tooling and final layup.
The shell had to clear the chassis, suspension and driver while remaining practical to manufacture. I led the team's SolidWorks surface development and split the design into machinable foam sections, so tooling constraints shaped the geometry from the start.
I generated HSMWorks toolpaths and machined more than fifty foam sheets. The sections were indexed, joined, filled and sanded into a full-size mould; alignment and finishing determined the surface quality of the final part.
Fibreglass was laid over the prepared mould, cured and trimmed to the chassis. The project connected team leadership and surface CAD with CAM, tooling, composite manufacture and final fit.
